Electrical capacitor



Patented June 24, 1941 ELECTRICAL CAPACITOR Paul McKnight Deeley, Plainfield, N. J., assignor to Cornell-Dubilier Electric Corporation, South Plainfield, N. J., a corporation of Delaware Application April 5, 1939, Serial N0. 266,076

4 Claims.

The present invention relates to electrical capacitors and among Athe objects of the invention is to provide an improved terminal arrangement for such capacitors.

The Vterminal arrangement proposed by the present invention is particularly well adapted for the construction of dry electrolytic capacitors although it will become obvious that the proposed improvement may be employed with equal advantage in wet electrolytic capacitors or any other type of capacitor presenting a similar problem of mounting and terminal arrangement. As is Well known, dry electrolytic capacitors contain a more or less viscous or pasty electrolyte disposed between the electrodes, the electrolyte being usually held within the pores of a fibrous spacer or separator, whereas in wetcapacitors a liquid electrolyte solution is used in a sealed container occupying the space between adjacent capacitor electrodes.

In the construction of electrolytic capacitors in the past, more particularlyin capacitors of the dry type, it has been customary to provide a terminal tab extending from an electrode of the capacitor by cutting cross-wise of the electrode foil a strip approximately 1/2" wide and by bending this strip so as to project from the'capacitor section. This tab is electrically secured to a terminal such as wire or screw terminal by riveting or in any other suitable manner, and the joint between the tab and the terminal protected from the action of the electrolyte by thoroughly covering it with a wax, pitch or any other suitable material to prevent corrosion by the electrolyte at the tab-to-terminal connection. Such a structure is satisfactory for capacitors employing plain or smooth foil in which case the space occupied by the capacitor is ample to facilitate the connecting operation during manufacture.

In the capacitors extensively used at present employing roughened or etched foil whereby the size of the anode may be reduced to 1/5 or less the size of the anode of the previous type employing non-etched foil, the above construction has been found to be highly unsuited and impractical.

As an example, an 8 mid. 450 volt capacitorL using plain foil requires an anode approximately 20" long by 3" wide whereby the end surface of the convolute capacitor section obtained by spirally winding the anode strip together with a cathode strip and interposed fibrous spacers into a roll has a diameter of about On the other hand, when using etched foil in a capacitor designed for the same operating voltage and electrical capacity, the end surface area is approximately 1A of the above value and it is readily seen that in this case the space available is insuiilcient to allow for a tab 1/2 wide and enabling the riveting and other assembly operations to be carried out in an easy and economical manner.

Accordingly, an object of the present invention is to provide an improved and economical mounting and terminal arrangement for an electrical capacitor. With this object of the invention in view the non-flattened portion of a wire terminal or tab is passed through a hollow metal piece or sleeve such as a rivet or eyelet mounted in an insulating cap 0r block closing an open end of the container or can housing the capacitor section. By swaging or otherwise deforming this sleeve a liquid tight seal and intimate engagement and electrical connection is effected with the extending portion of the wire tab. As will be appreciated, a terminal structure of this type besides greatly simplifying the assembly and manufacturing operation requires a relatively small mounting space thus allowing a great number of terminals to be mounted at a closer distance as required in the case of multiple capacitor units comprising a plurality of anodes or cathodes each connected to a separate outside terminal. The metal sleeve or eyelet which is preferably of film forming material such as aluminum may serve as a terminal or the end of the wire terminal may be extended sufiiciently to serve as the connecting means for the capacitor. Alternatively, a further terminal tab or lug of desired shape which may consist of different material such as copper may be secured to the sleeve or eyelet.

As is well known, electrolytic capacitors when overloaded or subjected to adverse operating conditions become hot whereby gases are developed within the container or can housing the capacitor section. If this condition continues for a more or less prolonged time it may lead to a rapid deterioration or complete destruction of the capacitor. To avoid this danger, there is usually provided a vent in the casing or can housing the capacitor section. This vent is designed to open at a predetermined excess gas pressure developed within the capacitor to allow excess gas to escape from Within the can to the outside. One generally known form of vent consists of a punctured rubber cap or diaphragm suitably mounted in a portion of the container wall preferably the cover or closure disc and adapted to become distended by the action of the excess pressure so as to open the puncture and allow the undesired gases to escape.

This type 0f vent has various disadvantages which under circumstances may impair its proper function and reliability after prolonged use. Such a disadvantage is the fact that the operation is substantially impaired with age on yaccount of the deterioration or hardening of the rubber. Another disadvantage is due to the puncture or pin hole in the rubber diaphragm becoming clogged with foreign matter or precipitated salts from the electrolyte resulting in a substantial impairmentor complete interruption of the eectiveness of such a vent construction.

Accordingly, a yfurther object of the invention is to provide a novel safety vent for electrolytic devices.

Still another object is to provide a vent which is highly reliable and positive in operation.

The above and iurther objects and aspects of the invention will become more apparent from the following detailed description taken with reference to the accompanying drawing forming parts ci this specilicationV and wherein:

Figure l is a vertical cross-section through an electrolytic capacitor constructed in accordance with the invention,

Figure 2 is a fractional view of a capacitor shown in Figure i showing a modiied terminal arrangement',

Figures 3 and d are further partial views illustrating modied terminal arrangements embody- Y Y ing the improvements of the invention.

Similar reference numerals identify similar parts throughout the different views of the drawing.

Referring to the drawing, Figure l shows a dry electrolytic capacitor comprising'a metal can i0 closed at one end and having inserted therein a coivdnte capacitor section Il comprising two or more eiectrcde strips separated by suitable spacing strips such as gauze or paper in a manner well known to .those skilled in the art. The can i is formed with a shoulder or bead near its open end to provide a seat for an insulating end piece or closure disc I3.

densation product of phenol and formaldehyde known by the trade name of Bakelite although other insulating Vmaterials may be used as will the ring I5 when the-end of the can is spun over in the manner described.

Y The positive or anode terminal tab consists of a unitary wire member l2 of film forming metal such as aluminum having a attened portion connected to the anode such as bywa staking or riveting operation or in any other suitable manner adapted to ensure emcient electrical Vcontact between the tab and the electrode and to provide sumcient mechanical support. There is further provided in the embodiment shown a hollow metal piece such as a rivet or sleeve preferably consisting of film forming material such i projects beyond the disc I3 and in order toy e'ect e 'Ihe terminal lug 22 in this case may consist of Y The latter consists preferably of moldable material such as a conbe obvious. The disc lS-has a peripheral depres- Y ring' l, after having been assembled together are clamped and nrmly held in position by beading or spinning the edge of the can against the ring le, also eecting thereby a liquid tight seal between the disc I3 and the can lil.

The capacitor shown may be of the commonly known type wherein the cathode or unlmed electrodeis connected to the metal can4 serving as the negative terminal of the capacitor. To thisiend a terminal lead or tab 'le projecting fromthe cathode and which may be integral connection with the wire tab l2 the uppernonflattened portion of the tab is inserted in the sleeve or rivet 20and the latter deformed such as by swaging it by means of a suitable tool in such a manner as to effect an intimate engagement resulting in efficient electrical contact between the sleeve and wire tab. 'Ihe projecting wire may be of suiicient length to serve as a connecting terminal for the capacitor ora separate soldering terminal 22 or the like may be provided having a sleeve 2| tting over the sleeve or rivet 20 and mounted or anchored in the disc I3 similar to the sleeve 20. In this case, all the three members; that is, the wire tab l2 and the sleeves 2t and 21| will Vbe forced intol tight engagement by the deforming or swaging operation a different metal such as copper as there is no longer any danger of the electrolyte coming into contact with the connecting joint between the lug and the sleeve or rivet 20 thus removing any possibility of corrosion at thisjoint.

The mounting lugs l@ and llwhich may be of any desired number and arranged in a de-Y sired relative position greatly facilitate the mounting of the capacitor upon 'a panel member or support by passing the lugs through suitable openingsv in the panel and twisting or deforming them to lock and secure the capacitor tothe panel. A V

In connection with the use of certain aluminum can or metal encased electrolytic capacitors of the above described or any other type the circuit wherein the condenser is used may be of such that where the can o the capacitor forms one of the terminals, it may become advisable or necessary to electrically insulate the can from a metal chassis or base upon which the capacitor is mounted. For this purpose it is customary to provide an insulating washer between the can and the panel. This expedientl however does Y not suiice in many cases because the can may with the cathode foil or secured thereto in any Y then be at an elevated electrical potential in relation to the panel or chassis or toother exposed or accessible circuit components. Such a condition may constitute an actual hazard in the use 'of such an apparatus. Y

According to a further feature of the invention,

the aforementioned drawback Vis eliminated by coating Vthe exterior surface of the met-ai can or container'r housing the capacitor section with The head of the a thin layer of insulating material such as cellulose acetate. resin, varnish preferably a phenolic condensation productl such as Bakelite varnish, rubber or any other'material having suitable characteristics to provide a closely bonded insulating film or coating shown at 23 in the drawing. i

Referring to the drawing, Figure 2, there is shown a modified terminal construction according to the invention wherein the rivet or sleeve Il is dispensed with and the wiretab directly in. serted in the sleeve 2l of the terminal or soldering lug 22. For this purpose the latter is molded or otherwise mounted in the insulating cap or disc I3. In order to prevent corrosion by the electrolyte coming in contact with the joint between the terminal tab and the sleeve 2i, the disc I3 is formed with a central recess on. its underside adapted to receive a washer 28 of easily deformable material such as rubber. 'I'he wire tab I 2 has an enlarged portion or boss 2l abutting against the washer 28 in the assembled condition while a further insulating disc 21 is placed against the underside of the disc I3 in such a manner as to deform the washer 2i when the elements are clamped together during the beading or spinning of the edge of the container against the mounting ring I 5. In order to facilitate assembly of the tab I2 and disc l1 the latter is preferably constructed with a radial slot extending from the outer periphery to the center to permit of lateral insertion of the nonflattened portion of the tab. In the example shown this slot would be at right angle to the plane of the drawing.

Referring to Figure 3 there'is shown an embodimeht of a terminal construction wherein the metal piece mounted in the disc IJ has the form of a solid rivet having a terminal lug II clamped between its outer flange and the disc I3 and'having a rubber washer interposed between its inner flange and the disc I3. The inner end of the rivet is formed` with a tubular extension or sleeve adapted to receive the non-flattened end of the wire tab I2 and being deformed such as by swaging it to effect a firm mechanical and electrical connection between the tab I2 and the rivet 2l. In this case the latter should be of iilm forming metal such as aluminum similar to the 'anode to prevent lcorrosion at the connecting Joint.

'I'he embodiment according to Figure 4 is simliar to Figure 1 and comprises a terminal sleeve 3| having a ange embedded or molded in the disc I3 spaced sumciently from the inner surface of the disc to avoid contact with the electrolyte within the can, and a separate terminal lug Il having a tubular extension or sleeve 32 tting over the sleeve 3|. The sleeves II and I2 and the non-flattened portion of the wire tab are connected and held in firm engagement by a deforming operation-in a manner similar as in the foregoing constructions.

In order to relieve the capacitor of excess gases developed during operation there is provided an improved vent`consisting of a metal alloy ring 3l. Figure 2, taking the place of the rubber washer Il in Figure 1. 'I'he former consists of a metal alloy of such composition as to melt at a predetermined temperature thereby allowing excess e temperature. As will tantalum, titanium,

tion with lead, tin or bismuth.

A simple method of producing an'alloy of this type consists in using an ordinary steel pot in which is fused at first the metal of highest melting point whereupon the other metals are added in succession corresponding to their melting points; that is; the metal with the lowest melting point being added last. The alloy is thoroughly mixed and then molded in an ordinary metal die into a desired shape or it may be rolled into sheet form and then cut. Alternatively, the ilnal shape may be obtained by a pressing or extruding operation in a manner well understood. In electrolvtic capacitors using plates or metal foil of :dim forming material such as aluminum, etc., or an alloy of two or more such metals, the electrodes are generally subjected to anodic treatment or oxidation to form an insulating iilm acting as the dielectric in the finished capacitor. 'I'he film obtained by the anodic treatment or electrolytic formation apparently consists substantially of aluminum oxide and/or hydrated forms of aluminum oxide. The film surface possesses a certain porosity which increases as the temperature of the electrodes is increased. This increase of the porosity of the l:Illm surface is obviously due to the differ- "ent coemcient of expansion of the film surface and the conducting plate or foil forming the electrode. As a result of the increased porosity under high temperatures additional electrical losses are produced which in turn will entail a further temperature increase. This will result in a rapid and accumulative deterioration and iinal destruction of the capacitor unless means are provided to reliably and eiliciently relieve the capacitor of the excess gas at a definite excess Ibe appreciated. a vent of the type according to the invention is admirably suited for this purpose Justmentof the operating temperature by the proper choice of the alloy combination used for any given operating conditions. Another reason for the improved effectiveness and reliability of a vent construction according ing or otherwise, the

gas developed within the capacitor can to escape to the invention is the fact that the gasket is in intimate contact with the metal container housing the capacitor section. 'lhus when the capacitor becomes hot for any reason of overloadgenerated heat is quickly conducted by the metal of thecontainer to the gasket alloy material. In consequence thereof, a prompt functioning at a determined excess temperature is insured thereby preventing any dangemus condition immediately at its inception. In other words, in the proposed vent construction the cause itself of trouble that is'excess heat due to overloading determines the operation of the vent rather than the gas pressure as the reby enabling a critical adsult of such cause as in the case of the previous vent structures such as discussed hereinbefore.

As will be evident from the above the invention is not limited to the specific construction and arrangement of parts and methods of assem- -bly disclosed herein for illustration but that numerous modifications and variations may be resorted to differing from the exemplifications presented and coming within the broad scope and spirit of the invention as defined in the appended claims. The specification and drawing are accordingly to ,be regarded in an illustrative rather than a limiting sense.

I claim:

1. In combination with an electrolytic capacitor comprising a metal can and at least one filmed electrode mounted therein, a. molded insulating disc liquid-tightly secured to an opening of said can, a metallic sleeve xedly molded in said disc and projecting outwardly from said disc, a wire tab having one end secured to said electrode and having its opposite end inserted in said sleeve, said sleeve and tab being of the same material as said electrode, a. metallic terminal element having a anged sleeve tting over said rst sleeve being also xedly molded in said disc, both said sleeves being deformed into rm mechanical and electrical contact with each other and said tab.

2. In combination with an electrolytic capacitor comprising a metal can and at least one filmed electrode mounted therein, a molded insulating disc liquid-tightly secured to an opening of said can, a rst metallic sleeve having a anged end firmly molded in said disc and having its other end projecting outwardly from said discfa wire tab having one end secured to said electrode and having its opposite end inserted in said sleeve, said sleeve and tab being of the Y; same metal as said electrode, and a terminal element of different metal having a flanged sleeve fitting over said first 'sleeve also being molded in said disc, both said sleeves being crimped into firm mechanical and electrical contact with each other and said tab, and means for preventing access ofelectrolyte in said can to the joint between said sleeves,

3. The combination with any electrolytic capacitor comprising a container and a capacitorv section mounted in said container, of a molded insulating closure member secured to an opening of said container, a metallic sleeve embedded in said closure member and projecting outwardly therefrom, an electrical conductor having one end secured to an electrode of said capacitor section and having its opposite end inserted in said sleeve, said conductor and said sleeve being substantially of the same material as said electrode,

'and a terminal .element having a sleeve fitting 'end inserted in said sleeve, said conductor and sleeve being substantially of the same material, and a terminal element having asleeve fittingv over said first sleeve and being also molded in said insulating member, both said sleeves being deformed into rm mechanical and electrical engagement with each' other and said conductor.

PAUL MCKNIGHT DEELEY. 

